CPC A43B 23/026 (2013.01) [A43B 1/04 (2013.01); A43B 7/14 (2013.01); A43B 7/20 (2013.01); A43B 23/023 (2013.01); A43B 23/0205 (2013.01); A43B 23/025 (2013.01); A43B 23/027 (2013.01); A43B 23/028 (2013.01); A43B 23/0215 (2013.01); A43B 23/0225 (2013.01); A43B 23/0265 (2013.01); A43B 23/042 (2013.01); A43B 23/087 (2013.01); A43B 23/17 (2013.01); D05C 17/00 (2013.01)] | 13 Claims |
1. A method of forming an article of footwear, the method comprising:
forming an upper having a lateral portion, a medial portion and a vamp, the upper formed by:
securing a temporary substrate to a support,
connecting a first crossing yarn to the temporary substrate by positioning a first strand along a first side of the temporary substrate, positioning a second strand along a second side of the temporary substrate and piercing the temporary substrate to interlock the first strand with the second strand at selected locations along a length of the first crossing yarn,
connecting a second crossing yarn to the temporary substrate by positioning a first strand along the first side of the temporary substrate, positioning a second strand along the second side of the temporary substrate and piercing the temporary substrate to interlock the first strand with the second strand at selected locations along a length of the second crossing yarn, wherein the first crossing yarn, the second crossing yarn, or both the first and second crossing yarns include a fusible strand that softens when exposed to heat of a predetermined temperature and hardens upon cooling,
removing the temporary substrate to form a self-supporting textile including the lateral upper portion, medial upper portion and the vamp, and
applying heat to the upper to soften the fusible strand; and
coupling the upper to a sole structure to form the article of footwear;
wherein:
each interlocked first stand and second strand defines a stitch,
the first crossing yarn includes a first stitch adjacent a second stitch, and
a distance between the first stitch and the second stitch is less than five mm.
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